Packing material and method of manufacturing the packing material

ABSTRACT

A packing material including a plurality of discrete cushioning elements and methods for making the same. The discrete cushioning elements may be cellulosic cushioning elements. A flexible linkage may connect the plurality of discrete cushioning elements in the packing material. The packing material may also include a bottom cellulosic sheet connected to a top cellulosic sheet with the plurality of cellulosic cushioning elements positioned between the top cellulosic sheet and the bottom cellulosic sheet. The packing material may also be a molded packing material that includes bonds comprising adhesive and cellulosic fibers. The adhesive and cellulosic fibers of the bonds may be dispersed between the folds of each of the cellulosic cushioning elements.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Patent Application No. 63/054,853, filed Jul. 22, 2020, andtitled “PACKING MATERIAL AND METHOD OF MANUFACTURING THE PACKINGMATERIAL,” the entirety of which is incorporated herein by reference.

FIELD OF THE INVENTION

The invention relates to packing material, particularly packing materialthat includes a plurality of discrete cushioning elements made frompaper. The invention is also related to methods of manufacturing thesame.

BACKGROUND OF THE INVENTION

Various packing materials are used to secure items in shippingcontainers, including cardboard boxes, to thereby prevent damage tothese items if they move within the shipping container during shipmentor other impacts during shipping, such as being dropped or hit. Suchpacking materials include bubble wrap, expanded polystyrene (polystyrenefoam), and other plastic foam packing, which may be molded into blocksor into other shapes, peanuts, and inflated plastic bags (also known asair pillows). These plastic products may be discarded as waste afterthey have been used during shipping. Plastic waste takes a long time todecompose and produces carbon dioxide in the decomposition process. Inaddition, polystyrene foam does not readily biodegrade, and may takemany, many years to break down. With an increased awareness of thenegative effects of plastics and polystyrene foam on the environment,however, consumers are increasingly seeking to useenvironmentally-friendly, recyclable, and biodegradable products as apacking material. There are desired environmentally-friendly,recyclable, and biodegradable products that provide sufficientcushioning effects at an affordable cost.

SUMMARY OF THE INVENTION

In one aspect, the invention relates to a packing material including aplurality of cellulosic cushioning elements and bonds bonding theplurality of cellulosic cushioning elements to each other. Eachcellulosic cushioning element of the plurality of cellulosic cushioningelements has a plurality of folds and is formed into a shape. The bondscomprise adhesive and cellulosic fibers. The adhesive and cellulosicfibers of the bonds are dispersed between the folds of each of thecellulosic cushioning elements.

In another aspect, the invention relates to a method of manufacturingmolded packing material. The method includes filling a mold with aplurality of cellulosic cushioning elements; applying an aqueous slurryof cellulosic fibers and adhesive to the plurality of cellulosiccushioning elements in the mold; drying the aqueous slurry and theplurality of cellulosic cushioning elements to form a molded packingmaterial; and removing the molded packing material from the mold.

In a further aspect, the invention relates to a method of manufacturingpacking material. The method includes providing a cellulosic sheet. Thecellulosic sheet has a thickness and a face surface. The face surfacehas a surface area. The cellulosic sheet has a thickness direction andan orthogonal direction that is orthogonal to the thickness direction.The method also includes compressing the cellulosic sheet to form acompressed cellulosic sheet; and twisting the compressed cellulosicsheet to form a crumpled cellulosic sheet.

These and other aspects of the invention will become apparent from thefollowing disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A shows a cellulosic cushioning element that can be used as apacking material according to a preferred embodiment of the invention.FIG. 1B shows an alternative cellulosic cushioning element that can beused as the packing material.

FIG. 2 is a shipping box containing an item and a plurality of thecellulosic cushioning elements in FIG. 1A.

FIGS. 3A-3D show a method and machine used to manufacture the cellulosiccushioning element shown in FIG. 1A. FIG. 3A shows a first step, FIG. 3Bshows a second step, FIG. 3C shows a third step, and FIG. 3D shows afourth step.

FIGS. 4A-4D show an alternate method and machine used to manufacture thecellulosic cushioning element shown in FIG. 1A. FIG. 4A shows a firststep, FIG. 4B shows a second step, FIG. 4C shows a third step, and FIG.4D shows a fourth step.

FIG. 5 is a perspective view of feeding rollers that may be used withthe method and apparatus shown in FIGS. 4A-4D.

FIGS. 6A and 6B are cellulosic cushioning elements that may be producedby the method and apparatus shown in FIGS. 4A-4D. FIG. 6A is acellulosic cushioning element that is produced without shaping by thefeeding rollers, and FIG. 6B is a cellulosic cushioning element that isproduced with the feeding rollers shown in FIG. 5.

FIGS. 7A and 7B each show a packing material with linkages connectingdiscrete cushioning elements. The packing material in FIGS. 7A and 7Buse the cellulosic cushioning elements shown in FIG. 1A as discretecushioning elements. FIG. 7A shows one way the linkage is attached tothe cellulosic cushioning elements, and FIG. 7B shows another way thelinkage is attached to the cellulosic cushioning elements.

FIG. 8 shows the packing material of FIG. 7B with alternative discretecushioning elements.

FIG. 9 shows the packing material of FIG. 7A with alternative linkages.

FIG. 10 shows another packing material with linkages connecting discretecushioning elements. The packing material in FIG. 10 uses the cellulosiccushioning elements shown in FIG. 1A as discrete cushioning elements.

FIG. 11 shows the packing material of FIG. 10 used on a bottle.

FIG. 12 shows a method of manufacturing the packing material shown inFIG. 9.

FIG. 13 shows another packing material using the cellulosic cushioningelements shown in FIG. 1A as discrete cushioning elements.

FIG. 14 shows further packing material using the cellulosic cushioningelements shown in FIG. 1A as discrete cushioning elements.

FIG. 15 is a cross-sectional view of the packing material shown in FIG.14 taken along line 15-15 in FIG. 14.

FIG. 16 is an alternate cross-sectional view of the packing materialshown in FIG. 14 taken along line 15-15 in FIG. 14.

FIG. 17 shows a variation of the packing material shown in FIG. 14.

FIG. 18 shows another variation of the packing material shown in FIG.14.

FIG. 19 shows a method and machine used to manufacture the packingmaterial shown in FIG. 14.

FIG. 20 shows a further packing material using the cellulosic cushioningelements shown in FIG. 1A.

FIG. 21 is a cross-sectional view of the packing material shown in FIG.20 taken along line 21-21 in FIG. 20.

FIG. 22 shows a method and machine used to manufacture the packingmaterial shown in FIG. 20.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The packing materials disclosed herein utilize a cushioning element 100as a base material. FIG. 1A shows a preferred cushioning element 100that may be used in the packing materials discussed further below. Thiscushioning element 100 is preferably a cellulosic cushioning element110, being formed from paper composed of cellulosic fibers. Othersuitable cushioning elements 100, as will be described in certainembodiments below, may also be used in the packing materials discussedherein. Paper is a preferred material used for the cellulosic cushioningelement 110, as paper is biodegradable. The paper used herein ispreferably recycled paper (e.g., previously-used paper). Varioussuitable basis weights and thicknesses may be used for the cellulosiccushioning elements 110 discussed herein and they may be varieddepending upon application. As will be described further below, thepaper is preferably crumpled into a shape that is preferably ball-likeor sphere-like or cylindrical. The cellulosic cushioning element 110 maybe relatively small in size, such as approximately 0.25 inch indiameter, or relatively large in size, such as approximately one inch indiameter. But such sizes are exemplary, and various other suitablediameters may be used. The crumpled cellulosic cushioning element 110thus includes a plurality of folds and crevices or air pockets formedbetween the folds of the cellulosic cushioning element 110.

An alternative cellulosic cushioning element 111 is shown in FIG. 1B.The paper used to form the alternative cellulosic cushioning element 111may be cut into thin strips (for example, 0.25 inch in width) and thenfolded a plurality of times into a shape to form the alternativecellulosic cushioning element 111. The alternative cellulosic cushioningelement 111 is thus folded to form a geometric shape, such as thesquare, shown in FIG. 1B. But other suitable geometric shapes may beformed. As with the cellulosic cushioning element 110, the alternativecellulosic cushioning element 111 includes a plurality of folds and airpockets formed between the folds and strips of paper.

The invention is not limited, however, to the sizes and shapes describedabove and shown in FIGS. 1A and 1B. The cellulosic cushioning element110 and alternative cellulosic cushioning element 111 may also becrumpled or folded to form elements having other shapes or formsincluding, for example, the form shown in FIG. 6A, below. Thealternative cellulosic cushioning element 111 may be used in place ofthe crumpled cellulosic cushioning element 110 in each of the packingmaterials discussed further below.

These cellulosic cushioning elements 110 may be used on their own aspacking material. FIG. 2 shows, for example, a shipping box 102 that hasan item-to-be-shipped 104 placed therein. The shipping box 102 may beany suitable shipping box including a carboard box. The cellulosiccushioning element 110 may be placed in the shipping box 102 to surroundthe item-to-be-shipped 104. The cellulosic cushioning element 110 iselastically deformable to absorb energy and protect theitem-to-be-shipped 104 but, even when crushed, provides additionalenergy (shock) absorbing to protect the item-to-be-shipped 104. Factorsimpacting the amount of energy absorbed that may be modified for thedesired protection include the weight of the paper, the volume or size(e.g., diameter) of the cellulosic cushioning element 110, and thedensity of the cellulosic cushioning element 110.

A method of forming the cellulosic cushioning element 110 and a machineassembly 200 used in this method will be described with reference toFIGS. 3A-3D. Initially a sheet 112 of paper is fed on top of a die 210and, in this embodiment, between a cover plate 212 and the die 210. Thesheet 112 includes a face surface 114 with a surface area. The sheet 112also has a thickness, which as discussed above, can be any suitablethickness. The sheet has a thickness direction and an orthogonaldirection that is orthogonal to the thickness direction. In FIG. 3A, thesheet 112 is fed in the orthogonal direction of the sheet 112. The sheet112 is nipped and fed by a feed roller 202. The feed roller 202 forms anip with a nip forming member, which in this embodiment is a feed plate204, but any suitable nip forming member may be used such as anotherroller. In this embodiment, the sheet 112 is a continuous sheet from aroll 116. However, the sheet 112 may be provided in other suitable formssuch a stack of sheets 112 that cut to size and fed one-by-one to thedie 210.

The die 210 has a cylindrical hole 214 with a taper 216 at the entranceof the die 210 forming a funnel shape. The sheet 112 is pressed throughthe die 210 with a plunger 220. The plunger 220 has a shape thatcorresponds to the shape of the die 210. In this embodiment, the plunger220 is cylindrical with a spherical tip 222, but any suitable shape maybe used. The cylindrical hole 214 of the die 210 has a diameter, and thediameter of the plunger 220 is smaller than the diameter of thecylindrical hole 214 so that the plunger 220 can be inserted into thecylindrical hole 214. The plunger 220 is lowered moving through a hole218 in the cover plate 212 to press the sheet 112 in a directioncrossing the orthogonal direction of the sheet 112, which is thethickness direction in this embodiment. The tip 222 of the plunger 220contacts the face surface 114 of the sheet 112 and pushes the sheet 112into the cylindrical hole 214 of the die 210. The sheet 112 has asurface area that is greater than the surface area of the cylindricalhole 214 at the exit of the die 210. As the plunger 220 pushes pressesthe sheet 112 into the taper 216 and the cylindrical hole 214 of the die210, the sheet 112 conforms to the shape of the die 210 and the plunger220 to form a shaped cellulosic sheet 118. Thus, in this embodiment, theshaped cellulosic sheet 118 has a hollow, cylindrical shape with aspherical tip. The plunger 220 is inserted into the cylindrical hole 214of the die 210 such that the plunger 220 discharges the shapedcellulosic sheet 118 from the exit (bottom) of the die 210.

When the sheet 112 is supplied by the roll 116 a cutter 224 may be usedto cut the sheet 112 to the appropriate length. In this embodiment, thecutter 224 is configured to move with the plunger 220 between the top ofthe die 210 and the feed plate 204. The cutter 224 cuts the sheet 112just before or as the tip 222 contacts the face surface 114 of the sheet112 to push the sheet 112 into the die 210.

After the shaped cellulosic sheet 118 exits the die 210, the shapedcellulosic sheet 118 passes between a first portion 230A and a secondportion 230B of a form 230 as shown in FIG. 3B. The first portion 230Aand the second portion 230B of the form 230 are then brought intocontact with each other to compress the shaped cellulosic sheet 118within a cavity 232 of the form 230 as shown in FIG. 3C. Each of thefirst portion 230A and the second portion 230B of the form 230 have aconcavity 234 formed therein that, when the first portion 230A and thesecond portion 230B are brought together, form a spherical cavity 232.In this embodiment each concavity 234 is hemispherical to form thecavity 232.

The form 230 also includes a catcher 240 to help catch the shapedcellulosic sheet 118 as it passes between the first portion 230A and thesecond portion 230B of the form 230. The catcher 240 of this embodimentincludes a plurality of teeth 242 that are splayed outward fromcontacting portions of the first portion 230A and the second portion230B of the form 230. The diverging angles of the teeth 242 helpcompress and guide the shaped cellulosic sheet 118 into the cavity 232as the first portion 230A and the second portion 230B are broughttogether. In this embodiment, the teeth 242 are interlocking teeth 242such that the teeth 242 of the first portion 230A mesh with the teeth242 of the second portion 230B.

With the shaped cellulosic sheet 118 compressed within the cavity 232the first portion 230A and the second portion 230B may be rotated aboutan axis extending in the direction in which the first portion 230A andthe second portion 230B are brought together (or separated). Rotatingthe first portion 230A and the second portion 230B of the form 230twists the shaped cellulosic sheet 118 and may help create additionalfolds and pockets in the resulting the cellulosic cushioning element110. To facilitate this process, each concavity 234 includes an outersurface 236 that is serrated. Compressing and twisting the shapedcellulosic sheet 118 forms the cellulosic cushioning element 110. Afterthe first portion 230A and the second portion 230B are rotated, thefirst portion 230A and the second portion 230B are separated by beingmoved in a direction opposite to the direction in which they werebrought together. The cellulosic cushioning element 110 is ejected fromthe form 230 as the first portion 230A and the second portion 230B areseparated as shown in FIG. 3D. These steps are repeated to formadditional cellulosic cushioning elements 110.

FIGS. 4A-4D show an alternate method for forming the cellulosiccushioning element 110 and a machine assembly 300 used in this method.As in the method and machine assembly 200 described above, a sheet 112of paper is used to form the cellulosic cushioning element 110. Althoughthe sheet 112 may be similar to those discussed above, the sheet 112 ofthis embodiment is preferably a strip of paper having a length (as willbe further discussed below) longer than its width. The sheet 112 isnipped and fed by a pair of feed rollers (a first feed roller 302 and asecond feed roller 304) and fed into an arcuate-shaped cylinder 310(herein arcuate cylinder 310), as shown in FIG. 4A. FIG. 5 is aperspective view of the first feed roller 302, the second feed roller304, and the arcuate cylinder 310.

The first feed roller 302 and the second feed roller 304 may have smoothouter surfaces, but they also may be configured to shape the sheet 112in the thickness direction as the sheet 112 is fed. As shown in FIG. 5,for example, the first feed roller 302 includes a groove 306. The groove306 of this embodiment is v-shaped, but any suitable shape may be used,including, for example a u-shape or a w-shape. The second feed roller304 has a corresponding surface, which in this embodiment is a v-shapedprotrusion 308. The protrusion 308 presses the sheet 112 into the groove306 to impart a shape corresponding to the groove 306 and protrusion 308to the sheet. FIG. 6A shows the cellulosic cushioning element 110produced using this method and machine assembly 300 when the sheet 112is fed with the first feed roller 302 and the second feed roller 304having smooth outer surfaces. The cellulosic cushioning element 110sheet shown in FIG. 6A has a plurality of folds with gaps therebetween.FIG. 6B shows the cellulosic cushioning element 110 produced using thismethod and machine assembly 300 when the sheet 112 is fed with the firstfeed roller 302 and the second feed roller 304 shown in FIG. 5. Thecellulosic cushioning element 110 sheet shown in FIG. 6B is similar tothe cellulosic cushioning element 110 shown in FIG. 1A, having aplurality of folds, but with a more cylindrical shape instead ofspherical.

As shown in FIG. 4A, the arcuate cylinder 310 has a channel 312 formedtherein with an inlet 314 and an outlet 316. The sheet 112 is fed intothe channel 312 through the inlet 314 and then slides through thechannel 312 until it contacts a ram 322 located at the outlet 316. Inthis embodiment, the sheet 112 (strip of paper) is fed into the channel312 to have a length longer than the length of the channel 312 and thesheet 112 waves back and forth within the channel 312. However, thelength of the sheet 112 is not so limited and it may be shorter, forexample.

When the sheet 112 reaches the desired length, it is cut with a cutter324. In this embedment, the cutter 324 is formed between an edge of theinlet 314 of the arcuate cylinder 310 and a plunger 326. The plunger 326is connected to a rotor 328 to rotate in a circle. As shown in FIG. 4B,the plunger 326 enters the inlet 314 of the arcuate cylinder 310 andcuts the sheet 112 as it does so. The plunger 326 rotates as it movesalong the channel 312 compressing the sheet against the ram 322 theplunger 326. The ram 322 and the plunger 326 of this embodiment aresimilar to the first portion 230A of the form 230 and second portion230B of the form 230 discussed above. The ram 322 and the plunger 326each include a hemispherical concavity 234 and, when brought together asshown in FIG. 4C, form a cavity 232 to compress the sheet 112 and formthe cellulosic cushioning element 110. As the plunger 326 continues torotate, the ram 322 pivots to open the cavity 232 and eject thecellulosic cushioning element 110 as shown in FIG. 4D.

The process shown in FIGS. 4A-4D repeats to form additional cellulosiccushioning elements 110. As can be seen in FIG. 4C, the next sheet 112is fed into the inlet 314 of the arcuate cylinder 310 after the plunger326 passes the inlet 314. Accordingly, the next sheet 112 is being fedas the previous sheet 112 is being compressed (FIG. 4C) and ejected asthe cellulosic cushioning element 110 (FIG. 4D).

While the plurality of cellulosic cushioning elements 110 are used in ashipping box 102 (as discussed above with reference to in FIG. 2), sucha configuration can be messy. When packing or unpacking theitem-to-be-shipped 104 the individual cellulosic cushioning elements 110can easily spill and scatter, requiring the need to clean up. To avoidthis issue, each cellulosic cushioning element 110 of a plurality ofcellulosic cushioning elements 110 can be connected to one another asshown in FIGS. 7A and 7B. FIGS. 7A and 7B show a packing materialaccording to a preferred embodiment of the invention. For clarity withthe other packing materials discussed herein, the packing material ofthis embodiment is referred to as a rope-like packing material 120.

The rope-like packing material 120 includes a plurality of discretecushioning elements 100 that are arrayed in a length direction A. Eachdiscrete cushioning element 100 of this embodiment is the cellulosiccushioning element 110 discussed above, but they are not so limited.Instead, each discrete cushioning element 100 may be, for example, apacking peanut 106 as shown in FIG. 8. The packing peanut 106 may be afoamed polymer resin material such as the s-shaped polystyrene foam.Other packing peanuts 106 may be used including biodegradable packingpeanuts that are made from resin material of a starch such as corn.

The rope-like packing material 120 will be further described withreference to FIGS. 7A and 7B, but it also applies to the othercushioning elements 100 shown in FIG. 8. The cellulosic cushioningelement 110 is arrayed in length direction A in an order. FIGS. 7A and7B show five cellulosic cushioning elements 110 each appended with adifferent letter (a-e). Each cellulosic cushioning element 110 isadjacent to at least one other cellulosic cushioning element 110. Forexample, cellulosic cushioning element 110 a is adjacent to cellulosiccushioning element 110 b, and cellulosic cushioning element 110 b isadjacent to both cellulosic cushioning element 110 a and cellulosiccushioning element 110 c. In this embodiment, the adjacent cellulosiccushioning elements 110 are spaced apart from each other with a gap(referred to as a first gap 122, herein) formed between the adjacentcellulosic cushioning elements 110, although other suitable embodimentsmay be possible where, for example, adjacent cellulosic cushioningelements 110 contact one another.

The adjacent cellulosic cushioning elements 110 are connected to eachother by a flexible linkage 124. The flexible linkage 124 is connectedto each cellulosic cushioning element 110 and spans the first gap 122between adjacent cellulosic cushioning element 110. In this embodimentthe flexible linkage 124 is a string. The cellulosic cushioning elements110 may be attached to the flexible linkage 124 using any suitablemethod, for example an adhesive. In FIG. 7A, the flexible linkage 124(string) is wrapped around each cellulosic cushioning element 110 atleast one time. In FIG. 7B, each cellulosic cushioning element 110 has ahole 126 formed through the diameter (central portion) of the cellulosiccushioning element 110, and the flexible linkage 124 (string) runsthrough the hole 126.

Other suitable flexible linkages 124 may be used. FIG. 9 shows anexample of the rope-like packing material 120 with an alternativeflexible linkage 124. The flexible linkage 124 of this embodimentincludes an upper tape 132 and a lower tape 134. Although any suitabletape can be used, each of the upper tape 132 and lower tape 134 ispreferably a paper (or cellulosic) strip that has a length much greaterthan its width (see FIG. 10). Paper is preferred, particularly when usedwith the cellulosic cushioning element 110 so that the entire rope-likepacking material 120 can be biodegradable and recyclable. In thisembodiment, the upper tape 132 and the lower tape 134 are aligned witheach other and sandwich the cellulosic cushioning element 110therebetween. An adhesive 136 is preferably applied to the inner sidesof each of the upper tape 132 and the lower tape 134 to bond the uppertape 132 and the lower tape 134 to each other and to the cellulosiccushioning element 110. Any suitable adhesive 136 may be used, but inthis embodiment, it is preferably a biodegradable adhesive.

In this embodiment, both the upper tape 132 and the lower tape 134 areused, but it is not so limited and the cellulosic cushioning element 110may be connected by a single tape (e.g., either the upper tape 132 orthe lower tape 134). In such a case, it is preferable to omit or removethe adhesive 136 from the portion of the tape in the first gap 122.

The flexible linkage 124 discussed above may be used with the discretecushioning elements 100 to form other packing materials. FIG. 10 showsanother packing material using the flexible linkage 124 discusses above.For clarity with the other packing materials discussed herein, thepacking material of this embodiment is referred to as a net-like packingmaterial 140. As with the other embodiments the cushioning element 100elements may be any suitable cushioning element, but in this embodiment,the cushioning element 100 is cellulosic cushioning element 110.

The cellulosic cushioning elements 110 of the net-like packing material140 are arrayed in two directions. The cellulosic cushioning elements110 are arrayed in the length direction A, as discussed above, and alsoare arrayed in a width direction B in an order. For example, thecellulosic cushioning element 110 b is adjacent to the cellulosiccushioning element 110 y and the cellulosic cushioning element 110 z inthe width direction B, in addition to the cellulosic cushioning element110 a and the cellulosic cushioning element 110 c in the lengthdirection A. The width direction B is a direction crossing the lengthdirection A, and in this embodiment, the width direction B isperpendicular to the length direction A.

The cellulosic cushioning elements 110 are also spaced apart with a gap(a second gap 142) formed between adjacent cellulosic cushioningelements 110 in the width direction B. One flexible linkage 124, a firstflexible linkage 144 connects the cellulosic cushioning elements 110 inthe length direction A and another flexible linkage 124, a secondflexible linkage 146) connects the cellulosic cushioning elements 110 inthe width direction B. In this embodiment, there are a plurality offirst flexible linkages 144 and a plurality of second flexible linkages146 that are connected together to form the net-like structure of thenet-like packing material 140. FIG. 10 shows the first flexible linkage144 and the second flexible linkage 146 with constructed using the tape(e.g., the upper tape 132 and the lower tape 134), but other suitableflexible linkages 124, such as string, may be used as discussed above.

The net-like packing material 140 may be used to pack anitem-to-be-shipped 104 in the manner shown above in FIG. 1A, but it mayalso be used in other suitable packing arrangements. For example, thenet-like packing material 140 may be used similarly to bubble wrap andbe wrapped around an item-to-be-shipped 104 such as a bottle 108, asshown in FIG. 11.

A method of forming the rope-like packing material 120 is shown in FIG.9, and a machine assembly 400 used in this method will be described withreference to FIG. 12. The cellulosic cushioning element 110 may beformed using any suitable method or machine including the machineassembly 200 and machine assembly 300 discussed above. The machineassembly 200 is shown in FIG. 12, for example. The machine assembly 400shown in FIG. 12 includes a first roll 402 of a strip of paper whichwill become the upper tape 132 and a second roll 404 of a strip of paperwhich will become the lower tape 134.

The upper tape 132 is stretched between the first roll 402 and a firstlaminating roller 412, and the lower tape 134 is stretched between thesecond roll 404 and a second laminating roller 414. Each of the firstlaminating roller 412 and the second laminating roller 414 have aplurality of recesses 416 formed in their exterior surface. Between therecesses 416 is a land 418. The first laminating roller 412 and thesecond laminating roller 414 are posited to form a bonding niptherebetween in which the recesses 416 of each laminating roller opposeeach other in the bonding nip and the lands 418 of each laminatingroller oppose each other in the bonding nip.

The adhesive 136 is applied to at least one of the upper tape 132 andthe lower tape 134. In this embodiment, the adhesive 136 is applied tothe upper tape 132 by an adhesive application unit 420. Alternatively,another adhesive application unit 420 may be used to also apply adhesive136 to the lower tape 134. The adhesive application unit 420 includes areservoir 422 holding the adhesive 136. The adhesive 136 is transferredfrom the reservoir 422 to an outer surface of applicating roller 424.The adhesive application unit 420 also includes a backing roller 426,which forms an adhesive application nip with the applicating roller 424.The upper tape 132 passes through the adhesive application nip and theadhesive 136 is applied by the applicating roller 424 to a surface(which will become an inner surface) of the upper tape 132. Othersuitable adhesive application units 420 may be used including, forexample, spray adhesive applicators.

After the cellulosic cushioning element 110 is formed and dischargedfrom the form 230, the cellulosic cushioning element 110 is guided tothe entrance of the nip by, for example, a chute 406. The cellulosiccushioning element 110 is then located in a cavity formed by twoopposing recesses 416 and separated from adjacent cellulosic cushioningelement 110 by opposing lands 418. The upper tape 132 is sandwichedbetween the first roll 402 and the cellulosic cushioning element 110,and the lower tape 134 is sandwiched between the second roll 404 and thecellulosic cushioning element 110. As the upper tape 132 and the lowertape 134 pass through the bonding nip without a cellulosic cushioningelement 110 between them, the upper tape 132 and the lower tape 134 arebonded to each other to form the first gap 122.

Another packing material is shown in FIG. 13. For clarity with the otherpacking materials discussed herein, the packing material of thisembodiment is referred to as a sandwich wrap 150. The sandwich wrap 150includes a top sheet 152 and a bottom sheet 154. Although any suitablesheet may be used, the top sheet 152 and the bottom sheet 154 arepreferably paper (cellulosic) sheets. The top sheet 152 is connected tothe bottom sheet 154 with a plurality of discrete cushioning elements100 positioned therebetween. As shown in FIG. 13, the discretecushioning elements 100 of this embodiment are cellulosic cushioningelements 110. In this embodiment, the cellulosic cushioning element 110are arrayed in the length direction A and in the width direction B.Although gaps may be present between adjacent cellulosic cushioningelements 110. The adjacent cellulosic cushioning elements 110 of thisembodiment contact each other. Each of the top sheet 152 and the bottomsheet 154 include an inner surface 156. An adhesive 136 is applied tothe inner surface 156 of each of the top sheet 152 and the bottom sheet154 to attach the cellulosic cushioning element 110 to the top sheet 152and the bottom sheet 154 and connect the top sheet 152 and the bottomsheet 154 to each other.

As noted above, the cushioning elements 100 may be positioned betweenthe top sheet 152 and the bottom sheet 154 with the cushioning elements100 spaced apart from each other. One such packing material is shown inFIGS. 14 and 15. For clarity with the other packing materials discussedherein, the packing material of this embodiment is referred to as awrap-like packing material 160. FIG. 15 is a cross-sectional view of thewrap-like packing material 160 taken along line 15-15 in FIG. 14. Thewrap-like packing material 160 of this embodiment has similarities tothe sandwich wrap 150. For example, the wrap-like packing material 160includes a top sheet 152 connected to a bottom sheet 154 with cellulosiccushioning elements 110 positioned therebetween. At least one of the topsheet 152 and the bottom sheet 154 includes a plurality of pockets 162.In this embodiment, both the top sheet 152 and the bottom sheet 154include a plurality of pockets 162. Each of the pockets 162 includes anopening 164. In the wrap-like packing material 160 shown in FIG. 15,each opening 164 of the top sheet 152 opposes a corresponding opening164 of the bottom sheet 154, forming a combined pocket. An area soundingeach pocket 162 or combined pocket is referred to herein as webbing area166. The top sheet 152 and bottom sheet 154 are adhered to each otherusing, for example, the adhesive 136 discussed above in the webbing area166.

At least one cellulosic cushioning element 110 is located in eachcombined pocket. In this embodiment, each pocket 162 includes aplurality of cellulosic cushioning elements 110. The plurality ofcellulosic cushioning elements 110 in each pocket 162 or combined pocketmay be bonded to each other with bonds comprising adhesive andcellulosic fibers, as will be described further below. Instead of boththe top sheet 152 and the bottom sheet 154 having a plurality of pockets162, pockets 162 may be formed in one of the top sheet 152 and thebottom sheet 154. FIG. 16 is a cross-sectional view of the wrap-likepacking material 160 taken along line 15-15 in FIG. 14, where aplurality of pockets 162 are formed in the bottom sheet 154 but not thetop sheet 152. In this embodiment, the top sheet 152 is bonded to thebottom sheet 154 such that the top sheet 152 covers the openings 164 ofthe plurality of pockets 162 in the bottom sheet 154.

To increase the flexibility of the wrap-like packing material 160, aplurality of holes 168 may be formed through both the top sheet 152 andthe bottom sheet 154, as shown in FIGS. 17 and 18. The wrap-like packingmaterial 160 shown in FIG. 17 has the holes 168 located between eachpocket 162 in the length direction A and in the width direction B.Another configuration for the wrap-like packing material 160 with holes168 is shown in FIG. 18 in which the holes 168 are formed ininterstitial portions between the pockets 162.

When a single cellulosic cushioning element 110 is located in eachcombined pocket of the wrap-like packing material 160, a modified methodand machine assembly 400 shown and discussed above with reference toFIG. 12 may be used. The first laminating roller 412 and the secondlaminating roller 414 may be longer and the machine assembly 200 isconfigured to place a plurality of cellulosic cushioning elements 110along the length of the first laminating roller 412 and the secondlaminating roller 414. Instead of the first roll 402 and the second roll404 being tape, they may be rolls of paper used to form the top sheet152 and the bottom sheet 154.

A method of forming the wrap-like packing material 160 shown in FIG. 16and a machine assembly 500 used in this method will be described withreference to FIG. 19. The bottom sheet 154 is provided with theplurality of pockets 162 formed therein. At a first station 502, theplurality of cellulosic cushioning elements 110 are filled in eachpocket 162. Optionally, at a second station 504, the cellulosiccushioning elements 110 in each pocket 162 may be bonded together. Thecellulosic cushioning elements 110 may be bonded together by anadhesive, which is preferably a biodegradable adhesive. Even morepreferably, an emulsion of water, adhesive, and cellulosic (paper)fibers are sprayed into each pocket 162 at the second station 504. Eachpocket 162 is conveyed and supported by a backing member, such as by thefirst laminating roller 412 discussed above, through a bonding nipformed between the first laminating roller 412 and a press roller 512.The top sheet 152 may be conveyed by the press roller 512 into thebonding nip and the top sheet 152 is bonded to the bottom sheet 154.Where the emulsion is used, the emulsion may then be dried resulting ina plurality of cellulosic cushioning elements 110 that are bonded bybonds comprising cellulosic fibers and the adhesive and/or a matrix ofcellulosic fibers and the adhesive, as discussed further below inconnection with the molded packing material 170.

Instead of using a sheet of paper alone as top sheet 152, a top sheet152 with pockets 162 filled with cellulosic cushioning elements 110 andoptionally bonded may formed in a manner similar to the bottom sheet154, as discussed above. This top sheet 152 with pockets may then bebrought together with the bottom sheet 154 in the bonding nip to formthe wrap like packing material shown in FIG. 15. Alternatively, two ofthe wrap-like packing materials 160 shown in FIG. 16 may be broughttogether to form the wrap-like packing material 160 shown in FIG. 15. Inany of these cases, the top sheet 152 and the bottom sheet 154 may bebonded together with an adhesive, which is preferably a biodegradableadhesive.

The cellulosic cushioning elements 110 discussed herein may also besuitable to make a polystyrene foam (or other plastic foam) replacement.FIGS. 20 and 21 show such a packing material according to a preferredembodiment of the invention. For clarity with the other packingmaterials discussed herein, the packing material of this embodiment isreferred to as a molded packing material 170. The molded packingmaterial 170 is shown in FIG. 20, and FIG. 21 is a cross section of themolded packing material 170 shown in FIG. 20 taken along line 21-21 inFIG. 20.

The molded packing material 170 will be formed into a shape in order topack the item-to-be-shipped 104. Such molded shape may include recessesand protrusions. For example, the molded packing material 170 shown inFIG. 20 includes a hemispherical cavity 172 in which a portion of theitem-to-be-shipped 104 can be placed. The molded packing material 170 ofthis embodiment includes a plurality of cellulosic cushioning elements110 that are formed into the desired shape and then joined together. Theplurality of cellulosic cushioning elements 110 may be joined togetherby bonds comprising adhesive and cellulosic (paper) fibers. In someembodiments, the plurality of cellulosic cushioning elements 110 may bejoined together by a matrix of cellulosic fibers, and in a preferredembodiment, a matrix of cellulosic (paper) fibers and an adhesive.Additional features of the bonds and matrix will be discussed below inconnection with the method of manufacturing the molded packing material170. Optionally, the outer surfaces of the molded packing material 170may be covered with an outer sheet 174. The outer sheet 174 ispreferably a cellulosic (paper) sheet.

A method of manufacturing the molded packing material 170 shown in FIG.20 will be described with reference to FIG. 22. First, a mold 520 havingthe desired shape is provided. The mold 520 may preferably be silicon.If an outer sheet 174 is used, the outer sheet 174 is placed into themold. The mold 520 is then filled with the cellulosic cushioningelements 110. Next, an emulsion of water, cellulosic (paper) fibers, andpreferably adhesive is sprayed into the mold 520 with the cellulosiccushioning elements 110. The emulsion flows around and between thecellulosic cushioning elements 110. In addition, the emulsion may alsoflow at least a portion of the way into crevices exposed on the outersurfaces of the plurality of cellulosic cushioning elements 110. If theouter sheet 174 is used, the outer sheet 174 may be placed on top of anexposed surface 176 of the cellulosic cushioning elements 110. Thecellulosic cushioning elements 110 with the emulsion is then removedfrom the mold 520, such as by turning the mold 520 upside down, and thendried to form the molded packing material 170. The drying step may alsotake place before removing the cellulosic cushioning elements 110 fromthe mold 520.

As the cellulosic cushioning elements 110 with the emulsion is driedbonds form between the folds of each of the cellulosic cushioningelements 110 and also between the cellulosic cushioning elements 110.The emulsion may also form, as it is dried, a matrix around thecellulosic cushioning elements 110, and the cellulosic cushioningelements 110 may be connected to each other by the cellulosic fibersand, when used, the adhesive of the matrix. The molded packing material170 may thus include a plurality of cellulosic cushioning elements 110that are interconnected to each other by cellulosic fibers. Thecellulosic cushioning elements 110 may retain some of the air pocketstherein, and the molded packing material 170 may also be described ashaving discrete groupings of air (gas) pockets interspersed within acellulosic (paper) mass.

As discussed above, factors impacting the amount of energy absorbedinclude the weight of the paper, the volume or size (e.g., diameter) ofthe cellulosic cushioning element 110, and the density of the cellulosiccushioning element 110. In this embodiment, the amount of emulsion andthe amount of the cellulosic fibers and the amount of adhesive in theemulsion may also be modified to create a packing material with thedesired strength and energy absorbing properties. The emulsionsdiscussed herein may be referred to herein as an aqueous slurry ofcellulosic fibers and adhesive. In the emulsions discussed herein thecellulosic fibers are preferably the same fibers as are used in thepaper for the cellulosic cushioning element 110. In addition, theadhesive of the emulsion is preferably a biodegradable emulsion.

Although this invention has been described with respect to certainspecific exemplary embodiments, many additional modifications andvariations will be apparent to those skilled in the art, in light ofthis disclosure. It is, therefore, to be understood that this inventionmay be practiced otherwise than as specifically described. Thus, theexemplary embodiments of the invention should be considered in allrespects to be illustrative and not restrictive, and the scope of theinvention to be determined by any claims supportable by this applicationand the equivalents thereof, rather than by the foregoing description.

1.-13. (canceled)
 14. A method of manufacturing packing materialcomprising: providing a cellulosic sheet having a thickness and a facesurface, the face surface having a surface area, the cellulosic sheethaving a thickness direction and an orthogonal direction that isorthogonal to the thickness direction; compressing the cellulosic sheetto form a compressed cellulosic sheet; and twisting the compressedcellulosic sheet to form a crumpled cellulosic sheet.
 15. The methodaccording to claim 14, wherein providing the cellulosic sheet includes:feeding a continuous cellulosic sheet from a roll of the continuouscellulosic sheet; and cutting of the continuous cellulosic sheet to formthe cellulosic sheet.
 16. The method according to claim 14, furthercomprising pressing the cellulosic sheet through a die to form a shapedcellulosic sheet, the cellulosic sheet being pressed in a directioncrossing the orthogonal direction, the die having an exit with an areathat is smaller than the surface area of the face surface of thecellulosic sheet, wherein the pressing step is performed before thecompressing step and the shaped cellulosic sheet is compressed in thecompressing step to form the compressed cellulosic sheet.
 17. The methodaccording to claim 16, wherein a plunger is used to press the cellulosicsheet through the die.
 18. The method according to claim 17, wherein thedie has a cylindrical shape with a diameter and the plunger has acylindrical shape with a diameter, the diameter of the plunger beingsmaller than the diameter of the die such that the plunger is pressedinto the cylindrical shape of the die, the shaped cellulosic sheethaving a hollow, cylindrical shape.
 19. The method according to claim18, wherein the plunger has a rounded tip and the shaped cellulosicsheet is open at a top end and rounded at a bottom end.
 20. The methodaccording to claim 14, wherein the cellulosic sheet is compressed withina cavity of a form.
 21. The method according to claim 20, wherein thecavity has an outer surface and the outer surface is serrated.
 22. Themethod according to claim 20, wherein the form has a first portion and asecond portion, and wherein the compressing step includes bringing thefirst portion into contact with the second portion to compress thecellulosic sheet within the cavity.
 23. The method according to claim22, wherein each of the first portion and the second portion include aconcavity, the concavity of the first portion and the concavity of thesecond portion creating the cavity of the form when the first portionand the second portion are brought together.
 24. The method according toclaim 23, wherein the concavity of each of the first portion and thesecond portion is a hemispherical shape.
 25. The method according toclaim 22, further comprising feeding the cellulosic sheet into a channelhaving an inlet and outlet, wherein, in the compressing step, the secondportion of the form is located at outlet of the channel and the firstportion of the form moves in the channel from inlet towards the outletwith the cellulosic sheet positioned therebetween to compress thecellulosic sheet between the first portion of the form and the secondportion of the form.
 26. The method according to claim 25, furthercomprising cutting the cellulosic sheet when the first portion of theform enters the inlet of the channel.
 27. The method according to claim25, further comprising shaping the cellulosic sheet in the thicknessdirection as the sheet is fed.
 28. The method according to claim 14,further comprising: placing the crumpled cellulosic sheet between afirst outer sheet of a cellulosic material and a second outer sheet of acellulosic material; and attaching the first outer sheet to the secondouter sheet.
 29. The method according to claim 28, wherein the crumpledcellulosic sheet has a width and each of the first outer sheet to thesecond outer sheet have a width that is less than the width of thecrumpled cellulosic sheet.
 30. The method according to claim 28, whereineach of the first outer sheet to the second outer sheet is a tape withan adhesive on surfaces of the first outer sheet to the second outersheet that face each other.